OBSERVING BOILER SAFETY RULES

The rules that follow are brief reminders of the possible consequences in a boiler plant ofinappropriate operator response or questionable action in maintaining the boiler plant. In allcases, follow the published or oral safety rules of your employer, jurisdiction, and the FederalOSHA safety regulations to avoid possible disciplinary actions. In addition, study the safetyguidelines of the manufacturer of your boiler.

NEVER ALWAYSNEVER fail to anticipate emergencies. Do notwait until something happens to start thinking.

ALWAYS study every conceivable emergencyand know exactly what moves to make.

NEVER start work in a strange plant withouttracing every pipeline and learning the locationand purpose of every valve. Know your job.

ALWAYS proceed to proper valves or switchesrapidly but without confusion in time ofemergency. You can think better walking thanrunning.

NEVER allow sediment to accumulate in gauge-glass or water-column connections. A falsewater level may fool you and make you sorry.

ALWAYS blow out each gauge-glass and water-column connection at least once a day.Forming good habits may mean longer life foryou.

NEVER give verbal orders for importantoperations or report such operations verballywith no record. Have something to back you upwhen needed.

ALWAYS accompany orders for importantoperations with a written memorandum. Use alogbook to record every important fact orunusual occurrence.

NEVER light a fire under a boiler without adouble check on the water level. Many boilershave been ruined and many jobs lost this way.

ALWAYS have at least one gauge of waterbefore lighting off. The level should be checkedwith the gauge cocks. You will not be fired forbeing too careful.

NEVER light a fire under a boiler withoutchecking all valves. Why take a chance?

ALWAYS be sure blow down valves are closedand proper vents, water-column valves, andpressure-gauge cock are open.

NEVER open a value under pressure quickly.The sudden change in pressure, or resultingwater hammer may cause piping failure.

ALWAYS use the bypass if one is provided.Crack the valve from its seat slightly and awaitpressure equalization. Then open it slowly.

NEVER cut a boiler in on the line unless itspressure is within a few pounds of headerpressure. Sudden stressing of a boiler underpressure is dangerous.

ALWAYS watch the steam gauge closely andbe prepared to cut the boiler in, opening thestop valve only when the pressures are nearlyequal.

NEVER bring a boiler up to pressure withouttrying the safety valve. A boiler with its safetyvalve stuck is nearly as safe as playing withdynamite.

ALWAYS lift the valve from its seat by the handlever when the pressure reaches about three-quarters of popping pressure.

NEVER take it for granted that the safety valvesare in proper condition. The power plant is noplace for guesswork.

ALWAYS raise the valve from its seat with thelifting level periodically while the boiler is underpressure. Test by raising to popping pressureat least once per year.

NEVER increase the setting of a safety valvewithout authority. Serious accidents haveoccurred from failure to observe this rule.

ALWAYS consult an authorized boiler inspectorand accept his or her recommendations beforeincreasing the safety-valve pressure setting.

NEVER change adjustments of a safety valvemore than 10 percent. Proper operationdepends on the proper spring.

ALWAYS have the valve fitted with a new springand re-stamped by the manufacture for changesover 10 percent.

NEVER tighten a nut, bolt, or pipe thread understeam or air pressure. Many have died doingthis.

ALWAYS play safe on this rule. The one that isgoing to break does not have a special warningsign.

NEVER strike any object under steam or air ALWAYS play safe on this rule. You cannot tell

pressure. This is another sure path to theundertaker.

which straw might break the camel’s back.

NEVER allow unauthorized persons to tamperwith any steam-plant equipment. If they do notinjure themselves, they may cause injury to you.

ALWAYS keep out loiterers and place plantoperation in the hands of qualified persons. Aboiler room is not a place for a club meeting.

NEVER leave an open blow down valveunattended when a boiler is under pressure orhas a fire in it. Play safe; memory can fail.

ALWAYS check the water level before blowingdown and have a second person watch thewater gauge level while you blow down theboiler. Close the blow down valve, and thenrecheck the water level. You will avoid dry-firingthe boiler this way.

NEVER allow anyone to enter a drum of a boilerwithout following OSHA rules for entering aconfined space.

ALWAYS make sure the boiler is cool to enter,has enough oxygen per OSHA rules, has a signby the entrance stating “Worker Inside”, has anemergency person at the entrance, and that allvalves going to and from the boiler are lockedand closed.

NEVER allow major repairs to a boiler withoutauthorization. If you do not break a law, youmay break your neck.

ALWAYS consult an authorized boiler inspectorbefore proceeding with boiler repairs.

NEVER try to light a second burner from theflames of the first on-line burner. You might beinviting a serious puff back.

ALWAYS follow the starting sequence of themanufacturer on multi-burner boilers, includingignition and main flame proving by installedburner controls, and you will avoid a furnaceexplosion.

NEVER attempt to light a burner without ventingthe furnace until clear. Burns are painful.

ALWAYS allow draft to clear furnace of gas anddust for prescribed purge period. Change draftconditions slowly.

NEVER fail to report unusual behavior of aboiler or other equipment. It may be a warningof danger.

ALWAYS consult someone in authority. Twoheads are better than one.

STANDARD OPERATIONAL SEQUENCES ANDPROCEDURES

Note: This Publication is to be viewed only as a guide.

1. PRE-OPERATION CHECKLISTØ Pre-operational checks should be completed before lighting-up any boiler.Ø Necessary to ensure the boiler plant is in a safe and efficient condition.

g. Chemical Cleaning / Boil OutØ For new or existing boilers with excessive deposits.Ø Should be done under supervision of experienced personnel / contractors

familiar with the hazards of such an operation.

h. Safety Checklist Prior To InspectionØ Before entering any boiler :

Ø Lock out and tag all equipment items with movable parts connected tothe boiler and fuel system and place a sign at the operating controlsindicating that a workman is in the boiler.

Ø Make sure it is properly isolated at ALL fuel, flue gas, steam and watersources; make sure it is properly vented and obtain an air sample tocheck for breathing quality. Use low voltage lights or explosion proofflashlights inside the boiler.

Ø Notify the person in charge at the site when beginning and uponcompletion of the inspection.

Ø Inspect with another person.Ø Always be aware of the nearest escape routes.Ø Before closing drum manholes and furnace doors, it is essential to

ensure that all personnel are out of the boiler.

i. Before Closing The BoilerØ Thoroughly inspect all available parts of the boiler’s interior, both the

waterside and the fireside. Ensure no tools, rags or other debris areleft lying around inside the boiler that could cause problems.

Ø Tubes and other areas that are not easily visible should be checkedusing other suitable methods i.e. push rods, mirrors, etc. All loosetubes and debris should be swept into a dustpan being careful not tosweep into tubes, drains, or blow-down connections.

Ø Check all internal piping, hangers, brackets, etc. to be sure they notbeen damaged during maintenance work.

Ø All sealing surfaces should be given a final check for dents, scratchesand gouges. Critical water or steam joints under pressure must bescraped then dressed off flat with a carborundum block, or similarabrasive surface if they were damaged.

Ø Replace all gaskets on the waterside and steam connections. Thecost is minor compared with the headaches from leakages later on.Use a graphite paste or other suitable paste to prevent sticking.

Ø Gas side gasket joints are not as critical, but require close inspectionand cleaning and replacement if necessary.

j. Testing The Gas Side For LeakageØ For a forced draught unit, the draft fan may be used to place the

furnace under high enough pressure by closing off the outlet damper.Passing a lighted candle along all the joints to be tested, tests thefurnace attachments, furnace seals and smoke-box seals. The effectsupon the flame will detect any leaks of air from the positive pressurefurnace to the atmosphere. Another method is to use a “soap” test,which must be thoroughly dried after the test.

Ø NOTE: For the first test, a manometer could be installed to give thehead pressure the fan can deliver against the closed damperoperating at normal speed. This data should be recorded for futurereference or fan testing.

- For an induced draft boiler, the same procedure may be followed, butthis case calls for the flame behaving differently i.e. the inwardsuction of air will pull the flame into the leak.

k. Water And Steam SystemsØ Visual survey all the areas of the plant to check for damage and

ensure no unauthorized persons tampered with the plant.Ø Do NOT refill a boiler while it is hot. Treated warm water should be

used. The boiler should be vented to permit air to escape.Ø Check the water level in the gauge glass (mid point) and all the gauge

glass valves are open.Ø Test true water level by opening the test cocks, starting with the

uppermost.Ø Open all the feed water supply valves.Ø If water level was low, use the manual bypass valve to raise the water

level to slightly below the midpoint of the gauge glass )i.e. headpressure from the hot well).

Ø Check the make-up water supply system to the hot well and whetherit shall function automatically i.e. check float condition and operation.

Ø Start the feed water pump.Ø Check the water treatment plant is in full operating condition.Ø Boiler vent valve and any steam line vents should be opened to bleed

air out as steam is raised.Ø Open the main steam valve bypass. When distribution manifold is up

to temperature and pressure, bypass valve is closed and main steamvalve is opened.

Ø Open all steam drains, including steam trap bypasses, when thebypass valve was opened.

l. Fuel SystemsCovers fuel oil and fuel gas supply to a boiler.Ø Check furnace internals for obvious signs of fuel leaks due to failure

of the fuel valves to shut off (oil).Ø Check the gas supply pressure is greater than the minimum

permissible.Ø Check the fuel oil temperatures (for heavy fuel oil).Ø Check all the fuel valves are in final position for light-up sequence.

The vent valves between the gas shut-off valve should be closed.

Ø Check all burner control panel lights are “Ready”. If not, check andrectify the faulty condition.

Safety devices are worthless if they are not kept in operating conditionand checked regularly. The fuel safety shut-off valves are no exception.To test the tightness of the safety shutoff valves, a general procedureshould be followed. It may slightly vary for different burner suppliers.

1. Ensure the draft fan is operating and close the safety shut-off valves.2. Open the main manual gas supply valve and the vent valve.3. Note the pressure gauge reading between the gas pressure regulator

and the first safety shut-off valve. It should stabilize at the “lock-up”pressure if the regulator is a tight shut off design.

4. Open the gas cock.5. Connect the rubber hose with the test valve to the first nipple.6. Close the vent valve and place the lower end of the test hose in a cup

of water.7. Observe if any bubbles are emanating from the hose end, which

would indicate the first shut-off valve is leaking.8. Move the hose to the second nipple and cap off first nipple.9. Place the hose end in the cup of water and close the gas cock.10. Open the first shut-off valve and close the gas cock. If bubbles are

observed, then the second (downstream) shut-off valve is leaking.11. Close the first shut off valve and the gas cock. The pressure gauge

after the second shut-off valve should read (kPa). Cap off secondnipple and ensure all lines have been vented and closed.

g. Air SystemsCovers the combustion air system and the instrument air system and/orplant air for oil atomizer:Ø Check the intake air dampers are open and clear of any debris or

obstructions.Ø Check both the primary and secondary air dampers are set and ready

for automatic operation.Ø Check the damper control system is ready to operate.Ø Check the flue dampers for readiness to operate.Ø Check the draft fans are clear, run free and ready to operate.Ø Check the instrument air supply lines are clear of water and pressure

is correct.Ø If atomizing air is being used for the fuel oil, clear the line of all

condensed water by draining and check its pressure.